Crate-erecting machine

ABSTRACT

A crate-erecting machine  50  for erecting a collapsible crate comprising a bottom wall panel, a pair of side wall panels hinged to the bottom wall panel, and a pair of end wall panels hinged to the bottom wall panel, comprises a magazine  51  for holding a stack of collapsed crates, an erecting mechanism  90  for erecting a crate held in the magazine  51 , a transfer mechanism  91  for transferring the crate to the erecting mechanism  90 , and a dispensing mechanism  60  for dispensing the crate from the magazine  51  to the transfer mechanism  91.

FIELD OF THE INVENTION

The present invention relates generally to the erection of collapsible crates and, in particular, to crate-erecting machines for erecting collapsible crates.

BRIEF DISCUSSION OF THE PRIOR ART

Some grocery store chains in Australia now require their fresh fruit and vegetable suppliers to ship produce to them in collapsible plastic crates. The grocery store chains typically supply the crates to their fresh fruit and vegetable suppliers in a collapsed configuration so that their suppliers consequently need to erect the crates themselves.

For example, one grocery store chain in Australia requires its fresh fruit and vegetable suppliers to ship produce to them in erected collapsible plastic crates of the type depicted in FIG. 1. The crate which is depicted in FIG. 1 includes a bottom wall panel, a pair of upstanding and opposing side wall panels which are hinged to the bottom wall panel, and a pair of upstanding and opposing end wall panels which are hinged to the bottom wall panel and which are latched to the upstanding side wall panels so that the end wall panels and the side wall panels are thereby inhibited from collapsing.

The grocery store chain supplies its collapsible plastic crates to its fresh fruit and vegetable suppliers in a collapsed configuration which is depicted in FIG. 2 so that its suppliers consequently need to erect the crates themselves. In the collapsed configuration, the end wall panels overlie the bottom wall panel, and the side wall panels overlie the end wall panels. The crate is erected by firstly pivoting the side wall panels relative to the bottom wall panel so that the side wall panels are upstanding with respect to the bottom wall panel. The end wall panels are then pivoted relative to the bottom wall panels so that the end wall panels are upstanding with respect to the bottom wall panel, and so that the end wall panels are latched to the side wall panels.

Another grocery store chain in Australia requires its fresh fruit and vegetable suppliers to ship produce to them in erected collapsible plastic crates of the type depicted in FIG. 3. Similarly to the crate which is depicted in FIG. 1, the crate which is depicted in FIG. 3 includes a bottom wall panel, a pair of upstanding and opposing side wall panels which are hinged to the bottom wall panel, and a pair of upstanding and opposing end wall panels which are hinged to the bottom wall panel and which are latched to the upstanding side wall panels so that the end wall panels and the side wall panels are thereby inhibited from collapsing.

The grocery store chain in question supplies its collapsible plastic crates to its fresh fruit and vegetable suppliers in a collapsed configuration which is depicted in FIG. 4 so that its suppliers consequently need to erect the crates themselves. In the collapsed configuration, the end wall panels overlie the bottom wall panel, and the side wall panels overlie the end wall panels. Also, one of the end wall panels slightly overlies the other end wall panel. The crate is erected by firstly pivoting the side wall panels relative to the bottom wall panel so that they extend outwardly from the bottom wall panel as depicted in FIG. 5. The end wall panels are then pivoted relative to the bottom wall panel so that they are upstanding with respect to the bottom wall panel. The side wall panels are then pivoted relative to the bottom wall panel so that they are upstanding with respect to the bottom wall panel, and so that the end wall panels are latched to the side wall panels.

Although collapsible plastic crates of the type depicted in FIGS. 1 and 3 can be erected by hand, it is usually not feasible for fresh fruit and vegetable suppliers who ship large amounts of fresh produce in those crates to erect them by hand due to the large number of crates which they need to erect. Consequently, such fresh fruit and vegetable suppliers usually employ one or more crate-erecting machines which are able to automatically erect the crates.

Robot Systems™ manufactures a crate-erecting machine which is specifically adapted to erect collapsed crates of the type depicted in FIG. 2 which are transferred to it by a conveyor from a remote dispensing system. In operation, collapsed crates are fed into the machine narrow end first, and are transferred one at a time to the erecting station where they are erected. Once a crate has been transferred to the erecting station, pneumatically operated side wall panel erecting assemblies which are located on either side of the crate are rotated by 90° onto the side wall panels of the collapsed crate such that the side wall panel erecting assemblies move from a vertical position to a horizontal position. The side wall panel erecting assemblies include clamps which clamp the ends of the side wall panels. The side wall panel erecting assemblies are then rotated by 90° back to the vertical position so that the clamped side wall panels are thereby pivoted by 90° to an upstanding position relative to the bottom wall panel of the crate.

While the upstanding side wall panels of the crate are held by the clamps of the side wall panel erecting assemblies, pneumatically operated end wall panel erecting assemblies are lowered so that they engage with the top of each end wall panel of the crate. The end wall panel erecting assemblies then raise the end wall panels to an upstanding position relative to the bottom wall panel, and latch the end wall panels to the side wall panels. The clamps of the side wall erecting assemblies then release the side wall panels, and the end wall panel erecting assemblies return to their home position. The erected crate is then ejected from the erecting station so that another collapsed crate can be transferred to the erecting station.

SWF™ manufactures a crate-erecting machine which is specifically adapted to erect crates of the type depicted in FIG. 3. The machine includes an input conveyor for transferring stacks of manually loaded collapsed crates to a lifting area of a crate dispenser where they are elevated above the input conveyor to a crate dispensing height by lift angles which are attached to vertically extending lift chains. The collapsed crates are loaded on to the input conveyor such that the narrow sides of the crates face the direction in which they are moved by the conveyor. A pneumatically operated lift assembly which includes a sprag clutch-type cam operation engages with the sides of the uppermost crate of the elevated stack and lifts that crate clear of the stack to a feed position.

As each crate is lifted off the elevated stack, the lift chains of the crate dispenser elevate the remaining crates in the stack to the crate dispensing height until all of the crates in the stack have been removed by the pneumatically operated lift assembly. Once this occurs, the lift chains lower the lift angles to receive another stack of crates from the conveyor.

When a crate is moved to the feed position, pneumatically operated crate end support angles pivot in and under the crate so that they support the crate, and the lift assembly releases the crate and returns to the elevated stack to remove the uppermost crate in the stack.

The side wall panels of the dispensed crate which is supported by the crate side support angles are opened by pneumatically operated overhead opening assemblies such that the side wall panels are pivoted by approximately 120° with respect to the bottom wall panel of the crate. In particular, the pneumatically operated overhead side wall panel opening assemblies are lowered over the sides of the crate so that they engage with the top of each side wall panel, and are then operated so that they pivot the side wall panels relative to the bottom wall panel. The dispensed crate is clamped in position by pneumatic clamps while the side wall panels are pivoted relative to the bottom wall panel. Once the side wall panels are opened, the clamps release the crate and the side wall panel opening assemblies return to their home position.

A pneumatic cylinder then moves the opened crate forward until the sides of the bottom wall panel of the crate engage with powered transfer belts of the machine which transfer the crate from the feed or dispensed position to an erecting position. While the crate is transferred from the feed position to the erecting position, the side wall panels of the crate are further pivoted relative to the bottom wall panels by ploughs so that the end wall panels of the crate are able to be opened without being hindered by the side wall panels. Pneumatically operated overhead assemblies are then lowered over the crate so that they engage with the top of each end wall panel. The overhead assemblies then open the end wall panels by pivoting the end wall panels relative to the bottom wall panel by approximately 90°. The overhead assemblies also pivot the side wall panels relative to the bottom wall panel so that the side wall panels are returned to the open position.

The crate with its opened side wall panels and upstanding end wall panels is then ejected vertically downwards through a fixed die which pivots the side wall panels relative to the bottom wall panel so that the side wall panels are upstanding with respect to the bottom wall panel, and are latched to the end wall panels. The erected crate falls through the die and onto an output conveyor which transports the crate clear of the machine.

Although the rate at which the Robot Systems™ and the SWF™ machines are able to erect crates is quite high, it would be beneficial to be able to erect crates at an even faster rate. Consequently, it would be desirable to have a crate-erecting machine that is able to erect crates at an even faster rate than the Robot Systems™ and the SWF™ machines.

Also, although the Robot Systems™ and the SWF™ machines are both able to erect crates which have end wall panels and side wall panels of various heights, the machines must be manually adjusted when the height of the end wall panels or the height of the side wall panels changes. Having to manually adjust the machines when the height of the end wall or side wall panels change can be time-consuming and expensive. Such machines are consequently not particularly suitable for use in situations such as at a crate-washing facility for example, where it is necessary to randomly erect crates which have end wall panels or side wall panels of various heights.

Moreover, it is not possible to erect crates of different types such as the types depicted in FIGS. 1 and 3 using either the Robot Systems™ machine, or the SWF™ machine. The Robot Systems™ machine is only able to erect crates of the type depicted in FIG. 1, and the SWF™ machine is only able to erect crates of the type depicted in FIG. 3.

Examples of other prior art crate-erecting machines are disclosed in European Patent Publication Nos. 1052087 A2 (Robot Systems) and 1081049 A2 (Frutmac). Similarly to the Robot Systems™ and the SWF™ machines mentioned above, the machines disclosed by the aforementioned published European patent documents operate such that crates which are erected by the machines travel through the machines with their narrowest side leading, and the machines are only able to erect crates at a maximum rate of fifteen crates per minute.

In addition, each time the height of the side or end wall panels of the crates erected by the machines disclosed in the aforementioned European patent documents change, manual changes need to be made to the settings of the machines so that they are able to properly erect the crates.

Various other known erecting machines are disclosed in Netherlands Patent Publication No. 1013830 C2 (Schoeller), Netherlands Patent Publication No. 1025167 C2 (Systemate), U.S. Pat. No. 4,596,544 A (Hull), U.S. Pat. No. 4,285,679 A (Wahle), U.S. Pat. No. 4,201,118 A (Calvert et al.), and U.S. Pat. No. 4,044,658 A (Mitchard).

SUMMARY OF THE INVENTION

It is an object of the present invention to overcome, or at least ameliorate, one or more of the deficiencies of the prior art mentioned above, or to provide the consumer with a useful or commercial choice.

Other objects and advantages of the present invention will become apparent from the following description, taken in connection with the accompanying illustrations, wherein, by way of illustration and example, a preferred embodiment of the present invention is disclosed.

According to a broad aspect of the present invention there is provided a crate-erecting machine for erecting a collapsible crate comprising a bottom wall panel, a pair of side wall panels hinged to the bottom wall panel, and a pair of end wall panels hinged to the bottom wall panel, the machine comprising a magazine for holding a stack of collapsed crates, an erecting mechanism for erecting a crate held in the magazine, a transfer mechanism for transferring the crate to the erecting mechanism, and a dispensing mechanism for dispensing the crate from the magazine to the transfer mechanism.

The magazine preferably includes a rear wall and a pair of side walls. The rear wall is preferably able to be moved relative to the side walls, and the side walls are preferably able to be moved relative to each other so that the crates held in the magazine are thereby able to be correctly positioned relative to the dispensing mechanism irrespective of the dimensions of the crates.

The crates which are held in the magazine may be manually or automatically fed to the magazine. For example, the crates which are held in the magazine may be automatically fed to the magazine by a conveyor.

Preferably, the erecting mechanism includes a pair of side wall panel lifting mechanisms for erecting the side wall panels of the crate.

In a preferred form, each side wall panel lifting mechanism includes a clamping mechanism operable to clamp on to one of the side wall panels of the crate, and a side wall panel pivoting mechanism operable to pivot the clamped side wall panel relative to the bottom wall panel of the crate.

The clamping mechanism may include a pair of clamping members for engaging with the side wall panel, and a pair of actuators operable to force the clamping members against the side wall panel such that the side wall panel is thereby clamped between the clamping members. Preferably, the actuators are hydraulic or pneumatic cylinders.

The side wall panel pivoting mechanism may include a support member, a pivot member secured relative to the clamping mechanism and the support member such that the pivot member is able to pivot relative to the support member, and an actuator operable to pivot the pivot member relative to the support member to thereby pivot the clamped side wall panel relative to the bottom wall panel of the crate. Preferably, the actuator is a hydraulic or pneumatic cylinder.

Preferably, the erecting mechanism includes a pair of end wall panel lifting mechanisms for erecting the end wall panels of the crate.

In a preferred form, each end wall panel lifting mechanism includes a panel engaging member for engaging with one of the end wall panels of the crate, and an end wall panel pivoting mechanism for pivoting the engaged end wall panel relative to the bottom wall panel of the crate.

The panel engaging member is preferably adapted to engage with a top of the end wall panel. In a particular preferred form, the panel engaging member is a claw member.

The end wall panel pivoting mechanism preferably includes an axle, a pivotable and extendable arm extending between the panel engaging member and the axle, and an actuator operable to pivot the arm about the axle to thereby pivot the engaged end wall panel relative to the bottom wall panel of the crate. It is preferred that the extendable arm of the end wall pivoting mechanism is a telescopic arm. The actuator is preferably a hydraulic or pneumatic cylinder.

The erecting mechanism preferably also includes an overhead rail, a carriage secured relative to the end wall panel pivoting mechanism and mounted on the rail such that the carriage is able to be moved relative to the rail, and an actuator operable to move the carriage relative to the rail. The actuator is preferably a hydraulic or pneumatic cylinder.

The erecting mechanism is preferably adapted to erect crates of the type depicted in FIG. 1 or FIG. 3.

It is preferred that the crate-erecting machine includes a plurality of erecting mechanisms which are each able to erect a different type of crate. In a particular preferred form, the crate-erecting machine includes a first erecting mechanism for erecting crates of the type depicted in FIG. 1, and a second erecting mechanism for erecting crates of the type depicted in FIG. 3.

Preferably, the transfer mechanism comprises a plurality of rotatable sprockets, a continuous drive chain trained around the sprockets, a projection which extends from the drive chain and which is able to engage with a crate dispensed from the magazine, a motor operable to rotate the sprockets such that the drive chain circulates around the sprockets, and a plurality of support rails for supporting the crate as it is transferred to the erecting mechanism.

Preferably, the machine is adapted so that crates are transferred to the erecting mechanism by the transfer mechanism such that a leading portion of each crate is the wider of an end or a side of the bottom wall panel of the crate. It has been found that the machine is able to erect crates at a faster rate if the crates are transferred in this manner.

It is preferred that the crate-erecting machine also includes a stopping mechanism operable to prevent a crate from being transferred beyond the erecting mechanism before the crate has been erected. In a preferred form, the stopping mechanism includes a rotatable axle, a stopping member secured relative to the axle, and an actuator operable to rotate the axle so that the stopping member is able to engage with a crate which is transferred to the erecting mechanism. The stopping mechanism may also include a sensor for sensing if a crate is being transferred to the erecting mechanism, wherein the actuator is responsive to the sensor. The actuator may be any suitable type of actuator. Preferably, the actuator is a hydraulic or pneumatic cylinder.

In a preferred form, the dispensing mechanism includes a lowering mechanism operable to lower a crate held in the magazine on to the transfer mechanism, and a clamping mechanism operable to prevent the other crates held in the magazine from being lowered on to the transfer mechanism while the crate is being lowered on to the transfer mechanism.

The crate-erecting machine preferably also includes a sensor for sensing the height of the side wall panels of the crates which are erected by the machine, wherein the erecting mechanism is responsive to the sensor. The sensor is preferably an infrared proximity sensor which preferably includes an infrared transceiver and a reflector.

The machine is preferably adapted so that it is able to randomly erect crates which have side wall panels of various heights without requiring manual adjustment of the machine. This makes the machine particularly suitable for use in situations such as at a crate-washing facility where it is often necessary to randomly erect crates which have end wall panels or side wall panels of various heights.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the invention may be more fully understood and put into practice, a preferred embodiment thereof will now be described with reference to the accompanying illustrations, in which:

FIG. 1 depicts a first type of prior art collapsible crate when the crate is erected;

FIG. 2 depicts the first type of prior art collapsible crate when the crate is collapsed;

FIG. 3 depicts a second type of prior art collapsible crate when the crate is erected;

FIG. 4 depicts the second type of prior art collapsible crate when the crate is collapsed;

FIG. 5 depicts the second type of prior art collapsible crate with its two side wall panels folded outwardly so that they do not overlie the two end wall panels of the crate;

FIG. 6 is a first perspective view of a crate-erecting machine for erecting crates of the type depicted in FIG. 1;

FIG. 7 is a second perspective view of the crate-erecting machine depicted in FIG. 6;

FIG. 8 is a third perspective view of the crate-erecting machine depicted in FIG. 6;

FIG. 9 is a fourth perspective view of the crate-erecting machine depicted in FIG. 6;

FIG. 10 is a front elevation of the crate-erecting machine depicted in FIG. 6;

FIG. 11 is a rear elevation of the crate-erecting machine depicted in FIG. 6;

FIG. 12 is a right end elevation of the crate-erecting machine depicted in FIG. 6;

FIG. 13 is a left end elevation of the crate-erecting machine depicted in FIG. 6;

FIG. 14 is a plan view of the crate-erecting machine depicted in FIG. 6;

FIG. 15 is an inverted plan view of the crate-erecting machine depicted in FIG. 6;

FIG. 16 is a first perspective view of a crate-erecting machine for erecting crates of the type depicted in FIG. 1 and FIG. 3;

FIG. 17 is a second perspective view of the crate-erecting machine depicted in FIG. 16;

FIG. 18 is a third perspective view of the crate-erecting machine depicted in FIG. 16;

FIG. 19 is a fourth perspective view of the crate-erecting machine depicted in FIG. 16;

FIG. 20 is a front elevation of the crate-erecting machine depicted in FIG. 16;

FIG. 21 is a rear elevation of the crate-erecting machine depicted in FIG. 16;

FIG. 22 is a right end elevation of the crate-erecting machine depicted in FIG. 16;

FIG. 23 is a left end elevation of the crate-erecting machine depicted in FIG. 16;

FIG. 24 is a plan view of the crate-erecting machine depicted in FIG. 16; and

FIG. 25 is an inverted plan view of the crate-erecting machine depicted in FIG. 16.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to FIGS. 6 to 15, a crate-erecting machine 50 includes a magazine 51 for holding a stack of collapsed crates of the type depicted in FIGS. 1 and 2. The magazine 51 includes a rear wall 52, and a pair of side walls 53 extending from the rear wall 52. The crates are placed horizontally in the magazine 51 such that an end wall panel of each crate is located adjacent to the rear wall 52 of the magazine 51 and such that each side wall panel of each crate is located adjacent to a respective side wall 53 of the magazine 51.

Machine 50 also includes a dispensing mechanism 60 for dispensing individual crates from the magazine 51. Dispensing mechanism 60 includes a lowering mechanism 61 for lowering the bottommost crate in the stack held in the magazine 51 relative to the other crates in the stack. Lowering mechanism 61 includes a pair of laterally separated horizontal support members 62 for supporting the bottom wall panel of the bottommost crate in the stack. Each support member 62 is secured to a respective pair of vertical cylindrical guide rods 63 which extend through cylindrical openings in a guide plate 64. Each guide plate 64 is hinged to a respective rod 65, and each rod 65 is hinged to a respective arm 66 which is secured to and extends laterally from a rotatable axle 67. An electric motor 68 is able to rotate the axle 67 such that the support members 62 move up and down in a reciprocating manner, and are therefore able to lower and raise the bottommost crate in the stack relative to the other crates in the stack.

The dispensing mechanism 60 also includes an upper clamping mechanism 70. Clamping mechanism 70 includes a pair of laterally separated horizontal clamp members 71 which are located adjacent to the side walls 53 of the magazine 51. Each clamp member 71 includes a lip 72 for supporting the bottom wall panel of the bottom crate which is held in the magazine 51.

A respective pair of horizontal cylindrical guide rods 73 is secured to each clamp member 71, and each guide rod 73 is received by a respective sleeve 74 such that the guide rod 73 is able to slide back and forth relative to the sleeve 74.

Each clamp member 71 is secured to a piston rod 75 of a respective pneumatic cylinder 76 such that the pneumatic cylinders 76 are able to move the clamp members 71 towards and away from each other. The clamp members 71 are able to be moved towards each other by the pneumatic cylinders 76 so that the lips 72 of the clamp members 71 are able to support the bottom wall panel of a crate which is held in the magazine 51. The clamp members 71 are also able to be moved away from each other by the pneumatic cylinders 76 so that the clamp members 71 are unable to support crates which are held in the magazine 51.

Dispensing mechanism 60 also includes a lower clamping mechanism 80. Clamping mechanism 80 includes a pair of laterally separated horizontal clamp members 81 located below the clamp members 71 of the upper clamping mechanism 70. Clamp members 81 are located adjacent to the side walls 53 of the magazine 51. Each clamp member 81 includes a plurality of projections 82 that are able to be received by recesses in the sides of the bottom wall panel of a crate held in the magazine 51.

A respective pair of horizontal cylindrical guide rods 83 is secured to each clamp member 81, and each guide rod 83 is received by a respective sleeve 84 such that the guide rod 83 is able to slide axially back and forth within the sleeve 84.

Each clamp member 81 is secured to a piston rod 85 of a respective pneumatic cylinder 86 such that the pneumatic cylinders 86 are able to move the clamp members 81 towards and away from each other. The clamp members 81 are able to be moved towards each other by the pneumatic cylinders 86 so that the clamp members 81 are able to support the bottom wall panel of a crate which is held in the magazine 51 and which is located below the clamp members 71 of the upper clamping mechanism 70. The clamp members 81 are also able to be moved away from each other by the pneumatic cylinders 86 so that the clamp members 81 do not contact any crates which are held in the magazine 51.

The crate-erecting machine 50 also includes an erecting mechanism 90 for erecting a crate which is dispensed from the magazine 51 by the dispensing mechanism 60, and a transfer mechanism 91 for transferring the dispensed crate to the erecting mechanism 90. The dispensing mechanism 60 is operable to dispense the crate from the magazine 51 to the transfer mechanism 91.

The transfer mechanism 91 includes a first sprocket 92 mounted on an axle 93, a second sprocket 94 mounted on an axle 95, and a third sprocket 96 mounted on an axle 97. A continuous drive chain 98 is trained around both the first sprocket 92 and the third sprocket 96, and a lower portion of the chain 98 which extends between the first sprocket 92 and the third sprocket 96 engages with the second sprocket 94. The upper portion of the drive chain 98 which extends between the first sprocket 92 and the third sprocket 96 rests on a horizontal support member 99 which is itself supported by a plurality of cross members 100.

A plurality of regularly spaced projections 101 extend from the chain 98, and an electric motor 102 is able to rotate the axle 97 such that the drive chain 98 is thereby caused to circulate around the first sprocket 92 and the third sprocket 96 such that the projections 101 on the upper portion of the drive chain 98 travel from the first sprocket 92 to the third sprocket 96.

The transfer mechanism 91 also includes a pair of laterally separated parallel support rails 103 for supporting a crate which is transferred to the erecting mechanism 90 by the transfer mechanism 91. The support rails 103 are located on either side of the drive chain 98, and extend from beneath the magazine 51 to past the erecting mechanism 90.

A bottom crate in a stack of crates which is held in the magazine 51 is able to be separated from the rest of the crates in the magazine 51 and deposited on the support rails 103 by operating the lower clamping mechanism 80 to clamp the crate which is located above the bottom crate in the stack, and then operating the lowering mechanism 61 of the dispensing mechanism 60 to lower the bottom crate on to the support rails 103. The chain 98 is circulated around the first sprocket 92 and the third sprocket 96 so that a projection 101 engages with the dispensed crate which rests on the support rails 103, and pushes that crate along the rails 103 until the crate reaches the erecting mechanism 90. This process is repeated until the machine 50 is stopped or until the magazine 51 is empty.

The crate-erecting machine 50 also includes a stopping mechanism 110 to prevent a crate which is transferred to the erecting mechanism 90 from being moved too far along the support rails 103.

Stopping mechanism 110 includes a pair of laterally separated stopping members 111 secured to a rotatable axle 112 such that the stopping members 111 extend laterally from the axle 112. A piston rod 113 of a pneumatic cylinder 114 is hinged to one of the stopping members 111 such that the stopping members 111 are raised above the support rails 103 when the piston rod 113 is extended by the pneumatic cylinder 114, and are lowered below the support rails 103 when the piston 113 is retracted by the pneumatic cylinder 114.

When a sensor 115 detects a crate being transferred to the erecting mechanism 90, the stopping members 111 are raised above the support rails 103 to prevent the crate from being moved too far along the support rails 103. Once the crate has been erected by the erecting mechanism 90, the stopping members 111 are lowered so that the erected crate can be moved away from the erecting mechanism 90 and ejected from the machine 50 by the transfer mechanism 91. While the crate is being erected by the erecting mechanism 90, the crate is maintained in the correct position along the rails 103 relative to the erecting mechanism 90 by the projection 101 which pushed the crate along the rails 103 to the erecting mechanism 90, and by the stopping members 111.

The erecting mechanism 90 includes a pair of side wall panel lifting mechanisms 120. One of the lifting mechanisms 120 is located further along the rails 103 than the other lifting mechanism 120. Each lifting mechanism 120 includes a respective pair of clamping members 121. Each clamping member 121 of each lifting mechanism 120 is located adjacent to a respective support rail 103. Also, each clamping member 121 is secured to a respective piston rod (not depicted) of a respective pneumatic cylinder 122 such that the pneumatic cylinder 122 is able to move the clamping members 121 of each lifting mechanism 120 towards and away from each other.

Each pneumatic cylinder 122 is secured to a first end of a respective pivot member 123, and each pivot member 123 is hinged to a respective vertical support member 124 such that the pivot member 123 is able to pivot relative to the support member 124. A piston rod 125 of a respective pneumatic cylinder 126 is secured to a second end of each pivot member 123. The pneumatic cylinders 126 are able to pivot the pivot members 123 relative to the support members 124 by extending and retracting the piston rods 125.

The piston rods 125 are able to be extended by the pneumatic cylinders 126 such that the clamping members 121 are rotated to a horizontal position, and such that the clamping members 121 of the each lifting mechanism 120 extend towards the clamping members 121 of the other lifting mechanism 120. The piston rods 125 are also able to be retracted by the pneumatic cylinders 126 such that the clamping members 121 are rotated to a vertical position which is depicted in FIGS. 6 to 15.

The clamping members 121 are rotated to the horizontal position by the pneumatic cylinders 122 so that when a collapsed crate is transferred to the erecting mechanism 90 by the transfer mechanism 91, the clamping members 121 are then able to be moved towards the ends of the side wall panels of the crate so that the ends of each side wall panel are clamped between the clamping members 121 of a respective lifting mechanism 120. The clamping members 121 are then rotated by 90° to the vertical position by the pneumatic cylinders 126 so that the clamped side wall panels of the crate are thereby also pivoted by 90° to a vertically upstanding or erect position relative to the bottom wall panel of the crate.

The clamping members 121 and pneumatic cylinders 122 of each side wall panel lifting mechanism 120 comprise a clamping mechanism 127 of the lifting mechanism 120.

The pivot members 123, vertical support members 124, and cylinders 126 comprise a side wall panel pivoting mechanism 128 of the lifting mechanism 120.

The erecting mechanism 90 also includes a pair of end wall panel lifting mechanisms 130. Each lifting mechanism 130 includes a claw member 131 for engaging with a collapsed end wall panel of a crate which is transferred to the erecting mechanism 90 by the transfer mechanism 91. Each claw member 131 is secured to a first end of a respective telescopic arm 132, and each arm 132 extends laterally from a respective axle 133. A piston rod of a respective pneumatic cylinder 134 is secured to each arm 132, and the pneumatic cylinder 134 is secured relative to the arm 132 such that the arms 132 and the axles 133 are able to be pivoted in a vertical plane by extending and retracting the piston rods of the pneumatic cylinders 134. In particular, when the piston arms of the pneumatic cylinders 134 are extended by the pneumatic cylinders 134, the arms 132 are pivoted downwardly so that the claw members 131 are lowered, and when the piston arms of the pneumatic cylinders 134 are retracted by the pneumatic cylinders 134, the arms 132 are pivoted upwardly so that the claw members 131 are raised.

Each axle 133 is secured to a respective carriage 135, and each carriage 135 is secured to an overhead rail 136 such that each carriage 135 is able to move back and forth along the rail 136. Each carriage 135 is also secured to a piston rod 137 of a respective pneumatic cylinder 138 which is secured relative to the rail 136. The carriages 135 are able to be moved back and forth along the rail 136 by extending and retracting the piston rods 137 relative to the pneumatic cylinders 138.

The claw members 131, telescopic arms 132, axles 133 and pneumatic cylinders 134 comprise end wall panel pivoting mechanisms 139 of the end wall panel lifting mechanisms 130.

After the side wall panels of a crate have been erected by the side wall panel lifting mechanisms 120 of the erecting mechanism 90, the claw members 131 of the end wall panel lifting mechanisms 130 are lowered on to the collapsed end wall panels of the crate until they rest on the end wall panels. While the claw members 131 rest on the end wall panels, the arms 132 are extended towards each other so that the claw members 131 are pushed along the upwardly facing surfaces of the end wall panels. The arms 132 are extended towards each other until the claw members 131 are pushed off the end wall panels. The claw members 131 are then pulled back by retracting the arms 132 so that the claw members 131 engage with the top of the end wall panels. The claw members 131 are pulled back until the end wall panels are erected and are latched to the erected side wall panels. The claw members 131 are wide enough so that they are able to force the ends of the end wall panels to latch with the side wall panels.

The crates depicted in FIGS. 1 and 3 are available in three different sizes: small, medium and large. Except for the height of the end wall panels and the side wall panels, the dimensions of the small, medium and large-size crates are identical. The small-size crate has the shortest end wall panels and side wall panels, and the large-size crate has the tallest end wall panels and side wall panels.

The machine 50 is able to randomly erect small, medium and large-size crates without requiring any manual adjustment. When a crate is initially dispensed to the transfer mechanism 91 by the dispensing mechanism 60, a pair of infrared proximity sensors 140 detect whether the crate is a small, medium or large-size crate. This information is used by the erecting mechanism 90 to correctly position the claw members 131 relative to the crate, and to pull the claw members 131 back by the correct amount to properly erect the end wall panels of the crate.

Each sensor 140 includes an infrared transceiver 141 which transmits infrared light towards an associated reflector 142 which is able to reflect the light back towards the transceiver 141 which is able to sense the reflected light. When a small-size crate is dispensed by the dispensing mechanism 60, the collapsed side wall panels of the crate are not located between the transceivers 110 and the reflectors 142 of the sensors 140 so that infrared light which is transmitted towards the reflectors 142 by the transceivers 141 is able to be reflected back to the transceivers 141 by the reflectors 142 so that the sensors 140 are thereby able to sense that the crate is a small-size crate.

When a medium-size crate is dispensed by the dispensing mechanism 60, infrared light which is transmitted by the transceivers 141 is only reflected by one of the reflectors 142 so that the sensors 140 are thereby able to sense that the crate is a medium-size crate. This is because one of the collapsed side wall panels of the crate prevents the infrared light which is transmitted by one of the transceivers 141 from reaching the reflector 142 which is associated with that transceiver 141.

When a large-size crate is dispensed by the dispensing mechanism 60, infrared light which is transmitted by the transceivers 141 is not reflected by either of the reflectors 142 so that the sensors 140 are thereby able to sense that the crate is a large-size crate. The reason that infrared light which is transmitted by the transceivers 141 is not reflected by either of the reflectors 142 is because both of the collapsed side wall panels of the crate prevent the infrared light which is transmitted by the transceivers 141 from reaching the reflectors 142.

Once the end wall panels and the side wall panels of the crate have been erected and latched to each other by the machine 50, the clamping members 121 of each side wall panel lifting mechanism 120 are moved away from each other by the pneumatic cylinders 122 so that the clamping members 121 release the side wall panels of the crate. Also, the claw members 131 are moved clear of the crate by raising them above the crate, and the stopping members 111 are lowered. The drive chain 98 is then circulated around the sprockets 92, 96 by the motor 102 so that the transfer mechanism 91 ejects the erected crate from the end of the machine 50 which is adjacent the erecting mechanism 90, and so that the next crate which has been dispensed by the dispensing mechanism 60 from the magazine 51 is transferred to the erecting mechanism 90 where it is then erected in the same manner. This process continues until the machine 50 is stopped or until all of the crates held in the magazine 51 have been erected by the machine 50.

In addition to the components of the machine 50 which have already been mentioned, the machine 50 also includes a frame 150 which the various other components and mechanisms of the machine 50 are secured relative to. Frame 150 includes a plurality of vertical frame members 151 of various lengths. A respective foot 152 secured to the lower end of each vertical frame member 151. Frame 150 also includes a plurality of horizontal frame members 153 which are secured relative to the vertical frame members 151.

A plurality of lifting lugs 154 are secured to the frame 150. A user-operable control panel 155 for controlling the machine 50, and an electrical equipment cabinet 156 are also secured relative to the frame 150. Cabinet 156 is connected to the control panel 155, and contains various electrical and other equipment for controlling the operation of the various mechanisms of the machine 50.

FIGS. 16 to 25 depict a crate-erecting machine 160 which is similar in many respects to the crate-erecting machine 50. Unlike the machine 50 which is only able to erect crates of the type depicted in FIG. 1, the crate-erecting machine 160 is able to erect crates of the type depicted in FIG. 1 and the type depicted in FIG. 3. For convenience, features of the machine 160 which are the same as, or which are similar to, features of the machine 50 are referenced using like reference numbers.

Machine 160 includes a magazine 51 for holding a stack of collapsed crates of the type depicted in FIG. 2 or FIG. 4. The magazine 51 includes a rear wall 52 and a pair of side walls 53. The rear wall 52 and each of the side walls 53 are secured to a respective sub-frame 161, and each sub-frame 161 is secured to a piston rod of a respective pneumatic cylinder 162. Also, four respective horizontal cylindrical guide rods 163 are secured to each sub-frame 161, and each guide rod 163 is received by a respective sleeve 164 such that the guide rod 163 is able to slide back and forth within the sleeve 164.

The rear wall 52 is able to be moved towards and away from the side walls 53 by respectively extending and retracting the piston rod of the pneumatic cylinder 162 which is secured to the sub-frame 161 which is in turn secured to the rear wall 52. The side walls 53 are able to be moved towards and away from each other by respectively extending and retracting the piston rod of the pneumatic cylinders 162 which are secured to the sub-frames 161 which are in turn secured to the side walls 53.

A stack of crates of the type depicted in FIG. 1 or FIG. 3 is placed horizontally into the magazine 51 of the machine 160 such that an end wall panel of each crate is located adjacent to the rear wall 52 of the magazine 51, and such that each side wall panel of each crate is located adjacent to a respective side wall 53 of the magazine 51. When a stack of crates of the type depicted in FIG. 1 is placed in the magazine 51, the side walls 53 are located closer to each other and the rear wall 52 is located further away from the side walls 53 than when a stack of crates of the type depicted in FIG. 3 is placed in the magazine 51.

Before a stack of crates can be placed in the magazine 51, it is necessary to ensure that the rear wall 52 and the side walls 53 are correctly positioned. If the rear wall 52 or the side walls 53 are not correctly positioned so that the magazine 51 is unable to properly hold the crates, the rear wall 52 or the side walls 53 must firstly be moved to the correct position.

The crate-erecting machine 160 also includes a first erecting mechanism 90 for erecting crates of the type depicted in FIG. 1, a second erecting mechanism 170 for erecting crates of the type depicted in FIG. 3, a transfer mechanism 91 for transferring crates to the first erecting mechanism 90 and the second erecting mechanism 170 as appropriate, and a dispensing mechanism 60 for dispensing crates from the magazine 51 to the transfer mechanism 90.

Similarly to the dispensing mechanism 60 of the crate-erecting machine 50, the dispensing mechanism 60 of the crate-erecting machine 160 is able to dispense the bottom crate of a stack of crates which is held in the magazine 51 to the transfer mechanism 91 by clamping the crate which is located above the bottom crate, and then lowering the bottom crate onto the transfer mechanism 91. The dispensing mechanism 60 of the machine 160 is able to repeat this process until the machine 160 is stopped or until its magazine 51 is empty.

A crate which is dispensed on to the transfer mechanism 91 of the crate-erecting machine 160 is transferred to either the first erecting mechanism 71 or the second erecting mechanism 170 of the machine 160 by the transfer mechanism 91 depending upon whether the crate is of the type depicted in FIG. 1 or FIG. 3. The machine 160 determines the type of the crate from the position of the rear wall 52 and side walls 53 of its magazine 51. If the machine 160 determines that the crate which is being transferred by the transfer mechanism 91 is of the type depicted in FIG. 1, the transfer mechanism 91 transfers the crate to the first erecting mechanism 90. If the machine 160 determines that the crate which is being transferred by the transfer mechanism 91 is of the type depicted in FIG. 3, the transfer mechanism 91 transfers the crate to the second erecting mechanism 170.

The design and operation of the first erecting mechanism 90 of the machine 160 are similar to the design and operation of the erecting mechanism 90 of the machine 50. However, unlike the erecting mechanism 90 of the machine 50, the pneumatic cylinders 122 of the first erecting mechanism 90 of the machine 170 are operable to move the vertical support members 124 of that mechanism towards and away from the support rails 103 such that the clamping members 121 of each side wall panel lifting mechanism 120 move towards and away from each other.

The second erecting mechanism 170 is similar to the first erecting mechanism 90 of the machine 160, except that the side wall panel lifting mechanisms 120 of the second erecting mechanism 170 are located further apart from each other so that they are able to clamp on to the more widely spaced apart side wall panels of a collapsed crate of the type depicted in FIG. 3. Also after the side wall panel lifting mechanisms 120 of the second erecting mechanism 170 clamp on to the side wall panels of a crate which is transferred to the erecting mechanism 170, the side wall panel lifting mechanisms 120 pivot the clamped side wall panels by approximately 135° instead of 90° so that the end wall panels of the crate are able to be erected without being obstructed by the side wall panels.

Another difference between the first erecting mechanism 90 and the second erecting mechanism 170 is that the claw members 131 of the second erecting mechanism 170 are relatively narrow compared to the claw members 131 of the first erecting mechanism 90. Once the side wall panels of a crate which has been transferred to the second erecting mechanism 170 have been pivoted by approximately 135° by the side wall panel lifting mechanisms 120, the claw members 131 of the second erecting mechanism 170 are lowered on to the collapsed end wall panels of the crate until they rest on the upper surfaces of the end wall panels. While the claw members 131 rest on the end wall panels, the claw members 131 are pushed along the end wall panels so that one of the claw members 131 is forced beneath the end wall panel which lies on top of the other end wall panel, and so that the claw members 131 are pushed off the end wall panels. The claw members 131 are then pulled back so that they engage with the top of the end wall panels. The claw members 131 are pulled back until the end wall panels are pivoted by 90° so that they are upstanding relative to the bottom wall panel of the crate and rest against vertical support members 171. The side wall panel lifting mechanisms 120 then pivot the side wall panels in the opposition direction to which they were originally pivoted until the side wall panels are perpendicularly upstanding with respect to the bottom wall panel and are latched to the end wall panels.

After a crate is erected by the first erecting mechanism 90 or the second erecting mechanism 135 of the machine 160, the erected crate is then ejected from the machine 160 by the transfer mechanism 91 so that the next crate which has been dispensed by the dispensing mechanism 60 is transferred to the first erecting mechanism 90 or the second erecting mechanism 170. This process continues until the machine 160 is stopped or until all of the crates held in its magazine 51 have been erected and ejected.

Throughout the specification and the claims, unless the context requires otherwise, the term “comprise”, or variations such as “comprises” or “comprising”, will be understood to apply the inclusion of the stated integer or group of integers but not the exclusion of any other integer or group of integers.

Throughout the specification and claims, unless the context requires otherwise, the term “substantially” or “about” will be understood to not be limited to the value for the range qualified by the terms.

It will be appreciated by those skilled in the art that variations and modifications to the invention described herein will be apparent without departing from the spirit and scope thereof. The variations and modifications as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein set forth.

It will be clearly understood that, if a prior art publication is referred to herein, that reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country. 

1. A crate-erecting machine for erecting a collapsible crate comprising a bottom wall panel, a pair of side wall panels hinged to the bottom wall panel, and a pair of end wall panels hinged to the bottom wall panel, the machine comprising a magazine for holding a stack of collapsed crates, an erecting mechanism for erecting a crate held in the magazine, a transfer mechanism for transferring the crate to the erecting mechanism, and a dispensing mechanism for dispensing the crate from the magazine to the transfer mechanism.
 2. The machine of claim 1, wherein the erecting mechanism includes a pair of side wall panel lifting mechanisms for erecting the side wall panels of the crate.
 3. The machine of claim 2, wherein each side wall panel lifting mechanism includes a clamping mechanism operable to clamp on to one of the side wall panels of the crate, and a side wall panel pivoting mechanism operable to pivot the clamped side wall panel relative to the bottom wall panel of the crate.
 4. The machine of claim 3, wherein the clamping mechanism includes a pair of clamping members for engaging with the side wall panel, and a pair of actuators operable to force the clamping members against the side wall panel such that the side wall panel is thereby clamped between the clamping members.
 5. The machine of claim 3, wherein the side wall panel pivoting mechanism includes a support member, a pivot member secured relative to the clamping mechanism and the support member such that the pivot member is able to pivot relative to the support member, and an actuator operable to pivot the pivot member relative to the support member to thereby pivot the clamped side wall panel relative to the bottom wall panel of the crate.
 6. The machine of claim 1, wherein the erecting mechanism includes a pair of end wall panel lifting mechanisms for erecting the end wall panels of the crate.
 7. The machine of claim 6, wherein each end wall panel lifting mechanism includes a panel engaging member for engaging with one of the end wall panels of the crate, and an end wall panel pivoting mechanism for pivoting the engaged end wall panel relative to the bottom wall panel of the crate.
 8. The machine of claim 7, wherein the panel engaging member is a claw member.
 9. The machine of claim 7, wherein the end wall panel pivoting mechanism preferably includes an axle, a pivotable and extendable arm extending between the panel engaging member and the axle, and an actuator operable to pivot the arm about the axle to thereby pivot the engaged end wall panel relative to the bottom wall panel of the crate.
 10. The machine of claim 7, wherein the erecting mechanism further comprises an overhead rail, a carriage secured relative to the end wall panel pivoting mechanism and mounted on the rail such that the carriage is able to be moved relative to the rail, and an actuator operable to move the carriage relative to the rail.
 11. The machine of claim 1, wherein the machine includes a plurality of erecting mechanisms which are each able to erect a different type of crate.
 12. The machine of claim 1, wherein the transfer mechanism comprises a plurality of rotatable sprockets, a continuous drive chain trained around the sprockets, a projection which extends from the drive chain and which is able to engage with a crate dispensed from the magazine, a motor operable to rotate the sprockets such that the drive chain circulates around the sprockets, and a plurality of support rails for supporting the crate as it is transferred to the erecting mechanism.
 13. The machine of claim 1, wherein the machine is adapted so that crates are transferred to the erecting mechanism by the transfer mechanism such that a leading portion of each crate is the wider of an end or a side of the bottom wall panel of the crate.
 14. The machine of claim 1, wherein the machine also includes a stopping mechanism operable to prevent a crate from being transferred beyond the erecting mechanism before the crate has been erected.
 15. The machine of claim 14, wherein the stopping mechanism includes a rotatable axle, a stopping member secured relative to the axle, and an actuator operable to rotate the axle so that the stopping member is able to engage with a crate which is transferred to the erecting mechanism.
 16. The machine of claim 15, wherein the stopping mechanism also includes a sensor for sensing if a crate is being transferred to the erecting mechanism, wherein the actuator is responsive to the sensor.
 17. The machine of claim 1, wherein the dispensing mechanism includes a lowering mechanism operable to lower a crate held in the magazine on to the transfer mechanism, and a clamping mechanism operable to prevent the other crates held in the magazine from being lowered on to the transfer mechanism while the crate is being lowered on to the transfer mechanism. 